U.S. patent number 4,070,719 [Application Number 05/719,498] was granted by the patent office on 1978-01-31 for cushioning element.
This patent grant is currently assigned to The Dow Chemical Company. Invention is credited to Charles W. Morgan.
United States Patent |
4,070,719 |
Morgan |
January 31, 1978 |
Cushioning element
Abstract
An improved cushioning element is provided which is prepared
from a synthetic resinous cellular resilient body. A plurality of
intersecting grooves are formed in the surface of the cushioning
element thereby providing a body-supporting surface of a plurality
of spaced-apart bosses generally independently deflectable and
recoverable.
Inventors: |
Morgan; Charles W. (Rolling
Hills, CA) |
Assignee: |
The Dow Chemical Company
(Midland, MI)
|
Family
ID: |
24890303 |
Appl.
No.: |
05/719,498 |
Filed: |
September 1, 1976 |
Current U.S.
Class: |
5/736; 428/167;
5/740 |
Current CPC
Class: |
A47C
27/146 (20130101); Y10T 428/2457 (20150115) |
Current International
Class: |
A47C
27/14 (20060101); A47C 027/08 () |
Field of
Search: |
;5/345R,355,361R,361B
;297/DIG.1 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Nunberg; Casmir A.
Attorney, Agent or Firm: Ingraham; R. B.
Claims
What is claimed is:
1. A cushioning element for seating or sleeping of humans and the
like, the cushioning element having a synthetic resinous resilient
cellular cushioning body, the cushioning body having ends and edges
at least a principal human body-supporting face adapted to be
disposed adjacent a human body when the cushioning element is in
use, the cushioning body defining on the body-supporting face a
plurality of grooves, the grooves having a width of from about
one-eighth to about three-eighths of an inch, the plurality of
grooves extending into the body and dividing the body-supporting
face and a portion of the body adjacent to the body-supporting face
into a plurality of adjacent spaced-apart bosses the grooves
terminating at a location adjacent the ends and edges thereby
providing an edge portion which is more resistant to compression
than the area having grooves with the further limitation the bosses
are individually deflectable and exhibit individual recovery when a
deflecting force is applied and removed respectively, thereby
providing a body-supporting face of a plurality of body-supporting
face bosses each at least partially deformable independent of
adjacent body-supporting face bosses.
2. The cushioning element of claim 1 in the form of a generally
planar slab.
3. The cushioning element of claim 2 having the form of a
mattress.
4. The cushioning element of claim 3 having a generally continuous
covering over the body-supporting surface.
5. A mattress for the support of the human body, the mattress
comprising a mattresscover generally enclosing a synthetic resinous
resilient cellulose cushioning body, the cushioning body having
ends and edges, at least a principal human body-supporting face
adapted to be disposed adjacent a human body when the cushioning
element is in use, the cushioning body defining on the body
supporting face a plurality of grooves, the plurality of grooves
extending into the body and dividing the body-supporting face and a
portion of the body adjacent to the body-supporting face into a
plurality of adjacent spaced-apart bosses with the further
limitation the bosses are individually deflectable and exhibit
individual recovery when a deflecting force applied and romoved is
removed respectively, thereby providing a body-supporting face of a
plurality of body-supporting face bosses each at least partially
deformable independent of adjacent body-supporting face bosses the
grooves terminating at a location adjacent the ends and edges
thereby providing an edge portion which is more resistant to
compression than the area having grooves with the further
limitation that the grooves have a width from about one-eighth of
an inch to three-eighths of an inch, the grooves are from one-half
to two and one-half inches in depth and are spaced on centers of
from about two and one-half to about four inches.
Description
Synthetic foam cushioning elements have been employed for seating,
mattresses and other comfort applications for many years. Such
cushioning elements have been prepared from foam rubber
compositions and molded into a wide variety of configurations.
Other popular synthetic resinous cushioning bodies are the
so-called flexible polyurethane foams. Bodies prepared from foam
rubber and flexible urethane foams have been shaped into principal
cushioning elements for various pieces of furniture. Oftentimes, in
order to reduce the apparent density of the cushioning element,
such cushioning elements have been prepared which define a
plurality of recesses, often of generally cylindrical configuration
extending inwardly from one or more of the surfaces thereof.
Oftentimes, the density of the synthetic cushioning element
provides a texture, consistency or degree of firmness different
from that which is desired. In some instances, a plurality of slits
have been formed in the cushioning body in order to provide a
softer cushioning element. In the production of cushioning elements
such as mattresses, usually it is desirable to provide such
articles with a varying degree of firmness or resistance to
deflection under the load provided a body resting thereon.
Generally, it is desirable to provide other cushioning elements in
varying degrees of firmness. Often, to provide such varying degrees
of firmness, it is necessary to mold cushioning element in
different molds which provide a configuration which gives the
different degrees of firmness desired or to alter a foam-forming
composition to provide foamed cushioning elements of varying
density and consequently varying firmness. In many instances
synthetic foam cushioning elements are found undesirable by users
because perspiration does not readily evaporate from a location
between the user's body and the cushioning element.
It would be desirable if there were available an improved synthetic
foam cushioning element.
It would be desirable if there were available an improved synthetic
foam cushioning element which could be readily prepared in varying
degrees of firmness.
It would also be desirable if there were available an improved
synthetic resinous cushioning element which permitted improved air
circulation when the user's, body was in contact with the
cushioning element.
It would also be desirable if there were available an improved
synthetic resinous mattress cushioning element.
These benefits and other advantages in accordance with the present
invention are achieved in a cushioning element for seating or
sleeping of humans and the like, the cushioning element having a
synthetic resinous resilient cellular cushioning body, the
cushioning body having at least a principal human body supporting
face adapted to be disposed adjacent a human body when the
cushioning element is in use, the cushioning body defining a
plurality of grooves, the plurality of grooves extending into the
body and dividing the body-supporting face and a portion of the
body adjacent to the body-supporting face into a plurality of
adjacent, spaced-apart bosses with the further limitation the
bosses are individually deflectable and exhibit individual recovery
when a deflecting force is applied and removed respectively,
thereby providing a grooved body-supporting face of a plurality of
body-supporting bosses each at least partially deformable
independent of adjacent body-supporting bosses.
Further features and advantages of the present invention will
become more apparent from the following specification taken in
connection with the drawing wherein:
FIG. 1 is a schematic, partly-in-section representation of a
mattress in accordance with the present invention;
FIG. 2 is a schematic representation of an alternate embodiment of
the present invention;
FIGS. 3, 4 and 5 depict alternate slit configurations useful for
the present invention.
In FIG. 1 there is schematically depicted a cushioning element or
mattress in accordance with the present invention generally
designated by the reference numeral 10. The mattress 10 has a
generally rectangular configuration, a first or upper major surface
11 and a second or lower major surface 12. The mattress 10 has a
periphery 13, sides 14, 15 and ends 16 and 17. The mattress 10
comprises a mattress cover 18 of conventional fabric and padding
construction and a mattress core or cushioning element 19. the
cushioning element 19 has a generally rectangular configuration,
edges and sides corresponidng to those of the mattress 10 and a
first major face 21 and a second major face 22. The cushioning
element 19 is prepared of a synthetic resilient foam such as a
composite foam as disclosed in U.S. Pat. No. 3,878,133 which has a
plurality of individual foamed synthetic resinous particles
dispersed throughout a synthetic resinous matrix such as
polyurethane foam. The teaching of U.S. Pat. No. 3,878,133 is
herewith incorporated by reference thereto. The cushioning element
19 on a first face 22 has defined therein a first plurality of
grooves 23 extending generally from side-to-side and a second
plurality of grooves 24 extending generally from end-to-end. The
grooves 23 and 24 as depicted in FIG. 1 are disposed generally at
right angles to each other and extend unto the cushioning element
in a direction mormal to the surface 22. As illustrated in FIG. 1,
the grooves 23 and 24 do not extend for the entire width and length
respectively of the mattress element 10 but terminate at a location
generally adjacent the ends and edges of the cushioning element.
The grooves 23 and 24, in effect, divide the cushioning element or
body surface into a plurality of generally independent bosses 26
which are separated from each other by the grooves and connected to
each other only at a location remote from the bodysupporting
surface such as the surface 22a. A similar set of grooves 23a are
disposed on face 22a opposed to face 22 of the cushioning element
17.
By the appropriate choice of groove width and groove depth, varying
degrees of firmness can be obtained. Generally it is desirable in a
mattress element employing a synthetic resinous foam to use a
groove width of from about one-eighth of an inch to three-eighths
of an inch and preferably from one-eighth to one-fourth inch, the
depth of the groove of from one-half to two and one-half inches and
when employed in a rectangular pattern such as depicted in FIG. 1,
adjacent grooves are spaced on about two and one-half to about four
inch centers. Generally it is desirable to maintain the groove
sufficiently wide that the independent bosses such as the bosses 26
can be deflected and recovered independently. If, for example, the
grooves of the cushioning element such as depicted in FIG. 1 have
zero width, in many foam cushioning material individual elements
can be depressed below the level of adjacent neighbors and will not
recover when the load is removed due to frictional engagement with
adjacent uncompressed foam adjacent the edges or sides of the
depressed boss. By providing a groove width of at least an eighth
of an inch such action is avoided and each element or boss acts as
a more or less independent cushioning element when subjected to a
load sufficient to cause minor compression. The groove width also
contributes substantially to comfort as the groove is a route for
the escape of moisture. Advantageously, the grooves such as the
grooves 23 and 24 do not extend entirely across the major faces of
a mattress such as the mattress 10 but terminate adjacent the edge
thereby providing a mattress having a peripheral or edge portion
which is significantly more resistant to compression than the
grooved area. Such edge stiffness generally is very desirable in a
mattress where occasionally it will be used as a seat and avoids a
soft edge configuration which, in general, for comfort purposes is
undesirable.
An alternate embodiment of the present invention is depicted in
FIG. 2 which is a bolster cushioning element generally designated
by the reference numeral 30. The cushioning element 30 has a
generally cylindrical body portion 31 and a cylindrical exterior
cushioning surface 32. The body defines a first plurality of
generally axially extending grooves 33 disposed on the cylindrical
surface 32 of the body 31. A second series of generally annular
outwardly facing grooves 34 extend circumferentially about the body
31 and intersect the grooves 33 to provide a plurality of bosses
35. For a bolster cushioning element such as the element 30 of FIG.
2, generally it is desirable to maintain the groove width at least
about an eighth of an inch, however, the depth and spacing are
primarily a matter of personal choice depending upon the rigidity
of the final bolster desired.
In FIG. 3 there is depicted schematically the groove pattern useful
for the practice of the present invention generally designated by
the reference numeral 36. The pattern 36 has two sets of grooves 37
and 38 generally disposed at right angles and a second set of
parallel slits 39 and 40 also disposed at right angles to each
other but displaced 45.degree. from the grooves 37 and 38, the
grooves 37, 38, 39 and 40 all having common points of
intersection.
In FIG. 4 there is schematically depicted an alternate groove
pattern useful for the present invention generally designated by
the reference numeral 45. Three series of parallel grooves are
employed, grooves designated 46, 47 and 48. The three groups of
parallel grooves are disposed at about 60.degree. to each other to
form a plurality of bosses having the configuration of an
equilateral triangle.
In FIG. 5 there is depicted an alternate pattern of grooves useful
in the present invention designated by the reference numeral 50.
The pattern comprises a plurality of overlapping circles 51 whose
centers lie on a square grid, each square of the grid having a side
less than the diameter of the circle.
Generally in the preparation of the cushioning elements in
accordance with the present invention, the number and arrangement
of the grooves is dependent on the softness desired in the
cushioning element, for example, the pattern of FIG. 5 employing
circles of about two inches in diameter such as might be cut with a
hole saw by moving a rapidly rotating saw into the foam, but not
through the foam, will provide a cushioning element with greater
initial defletion under minor load than if the pattern of FIG. 4 is
employed wherein the spacing of the parallel grooves is three
inches. For the preparation of mattresses and most cushioning
elements, the pattern of FIG. 1 is particularly desirable because
of the ease and rapidity with which it can be formed. Cushioning
foams can be grooved employing a plurality of circular saws of
equal diameter on a single rotating mandrel. The saw blades being
spaced apart the desired distance, the saw blades can then be
plunged into the foam to the desired depth, the foam moved relative
to the saw blades to provide grooves of the desired length, width
and depth. With some varieties of foam it is preferred to employ
abrasive wheels in place of saw blades if, in general, a smoother
finished groove is obtained.
As is apparent from the foregoing specification, the present
invention is susceptible of being embodied with various alterations
and modifications which may differ particularly from those that
have been described in the preceding specification and description.
For this reason, it is to be fully understood that all of the
foregoing is intended to be merely illustrative and is not to be
construed or interpreted as being restrictive or otherwise limiting
of the present invention, excepting as it is set forth and defined
in the hereto-appended claims.
* * * * *